Horizontal Ultrasonic Welding Thermoplastic Aerospace Components

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Solution Overview

Problem

Existing ultrasonic welding systems for thermoplastic materials face challenges in efficiently repairing aerospace components, particularly in creating strong bonds without adhesives and maintaining structural integrity.

Innovation Solution

The method involves arranging a thermoplastic patch on a thermoplastic aerospace component and using an ultrasonic horn to horizontally ultrasonic weld the patch to the component, creating a strong bond without adhesives and allowing for the repair of damaged areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional ultrasonic welding systems are used for thermoplastic aerospace components, then welding capability is provided, but bond strength and structural integrity are insufficient

Engineering Contradiction:

Improvebond strengthVSAvoidstructural integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies mechanical vibration through ultrasonic frequency oscillation of the horn to generate friction heat at the interface between the thermoplastic patch and component. This vibration-induced heating enables strong adhesive-free bonds while maintaining structural integrity through controlled thermal input and mechanical interlocking of the thermoplastic materials.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent utilizes parameter changes by controlling the ultrasonic welding parameters including frequency, amplitude, and duration to optimize the bonding process. By adjusting these parameters, the system achieves sufficient heat generation for strong bonds without excessive heating that would compromise structural integrity or cause damage to the aerospace component.

Inventive Principle:

Principle #35Parameter changes

2Strength

If adhesives are used to bond thermoplastic patch to component, then bond strength is achieved, but structural integrity and aerodynamic properties are compromised

Engineering Contradiction:

Improvebond strengthVSAvoidstructural integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent extracts and eliminates the need for adhesives by using direct ultrasonic welding of the thermoplastic patch to the component. This extraction of the adhesive layer maintains structural integrity and aerodynamic properties while achieving bond strength through pure mechanical/thermal welding processes.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism of adhesives with a mechanical/thermal welding system. The ultrasonic horn generates friction heat and mechanical interlocking to create bonds without chemical adhesives, thereby preserving the structural and aerodynamic properties of the aerospace component.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If ultrasonic welding is performed without proper horn engagement, then welding process is simplified, but bond quality and structural integrity deteriorate

Engineering Contradiction:

Improvewelding process simplicityVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by ensuring proper engagement of the ultrasonic horn with the thermoplastic patch before initiating the welding process. The horn is positioned and engaged with the patch surface in advance to ensure optimal contact and heat generation, which is essential for achieving strong bonds and maintaining structural integrity.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method effectively repairs thermoplastic aerospace components by creating strong, adhesive-free bonds that maintain the structural integrity and aerodynamic properties of the components.

Implementation Method 1

The thermoplastic patch is horizontal ultrasonic welded to the thermoplastic aerospace component using an ultrasonic horn

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

The ultrasonic horn moves back-and-forth along the surface of the second thermoplastic body during the ultrasonic welding

Methodology Applied

Scientific EffectFriction heating: Friction

Data Source

PatentUS20250033302A1Horizontal ultrasonic welding thermoplastic material

Publication Date: 2025.01.30 ROHR INC

AI summary

A repair method is provided during which a thermoplastic patch is arranged on a thermoplastic aerospace component. The thermoplastic patch contacts the thermoplastic aerospace component. The thermoplastic patch is horizontal ultrasonic welded to the thermoplastic aerospace component using an ultrasonic horn.